Carrier ZONECC3Z User Manual

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ZONECC3Z(AC/HP)01

Installation and Start-Up Instructions

TABLE OF CONTENTS

Page

SAFETY CONSIDERATIONS...................................................1

INSTALLATION CONSIDERATIONS....................................1

INTRODUCTION........................................................................1

INSTALLATION......................................................................1-4

• Check Equipment And Job Site ..............................................1-2

• Component Location And Wiring Considerations.....................2

• Install Components......................................................................2

• Install Zone Dampers...............................................................2-4

• Install Barometric Bypass Damper.............................................4

• Install Leaving Air Temperature (LAT) Sensor.........................4

• Install Heat Pump Temperature (HPT) Sensor ..........................4

SYSTEM WIRING...................................................................4-5

• Wire Thermostats ........................................................................4

• Wire Equipment...........................................................................4

• Wire Dampers..............................................................................5

• Wire Remainder...........................................................................5

UNDERSTANDING SYSTEM OPERATION......................6-7

SYSTEM SETUP....................................................................7-10

NOTE: Read the entire instruction manual before starting the
installation.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance,
or use can cause fire, electrical shock, or other conditions which
may cause personal injury or property damage. Consult a qualified
installer, service agency or your distributor or branch for informa­tion or assistance. The qualified installer or agency must use
factory-authorized kits or accessories when modifying this prod­uct. Refer to the individual instructions packaged with the kits or
accessories when installing.

Follow all safety codes and wear safety glasses. Have fire
extinguisher available. Read these instructions thoroughly and
follow all warnings or cautions attached to the unit. Consult local
and state building codes and Sheet Metal and Air Conditioning
National Association (SMACNA) for special installation require­ments.

Recognize safety information. This is the safety-alert symbol
When you see this symbol on the unit or in instructions and
manuals, be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, and CAU­TION. These words are used with the safety-alert symbol. DAN­GER identifies the most serious hazards which will result in severe
personal injury or death. WARNING signifies hazards which
could result in personal injury or death. CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.

INSTALLATION CONSIDERATIONS

Before the actual installation of a zoning system can begin,
decisions need to be made to determine the number and location of
zones. This affects duct and damper selections.

This instruction covers the physical installation and start up of the
Carrier 3-Zone system. Use this instruction to guide the actual
installation process after all the air side decisions have been made.

1. Install in non-condensing areas with ambients between 32°F
and 158°F.

2. A TXV is required on the indoor coil when used with all
residential split system equipment.

3. A separate transformer is not needed to power the 3-Zone
system. Up to five dampers may be used in each zone by
electrically connecting them in parallel.

4. Load calculations must be performed for each zone’s peak
demand. Size each zone duct for at least its peak demand plus
25%. Size equipment for the building block load, not the sum
of zone peak demands. It is important that the equipment not
be oversized.

5. When only two zone operation is needed, any two of the three
zone connections may be used. There is no inherent priority
dependent on zone number.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.
TXV on indoor coil is required with all residential split
system equipment.

INTRODUCTION

The Carrier 3-Zone system allows the air conditioning and heating
equipment to control temperatures in 3 distinct spaces or zones
within a building. Each zone has independent temperature settings
controlled by a conventional thermostat.

There are two distinct controllers:

• ZONECC3ZAC01 - Single Stage Heat / Single Stage Cool
using conventional single stage thermostats.

• ZONECC3ZHP01 - Three Stage Heat / Two Stage Cool
compatible for HP and multi-stage application thermostats and

.

equipment.

Each system controller is comprised of a three-zone controller and
a duct temperature sensor.

NOTE: Thermostats are purchased separately.
The comfort temperature settings can change automatically

through the use of schedules if programmable thermostats are
selected. This allows the Carrier 3-Zone to change the temperature
settings in zones to reflect occupancy or usage. The Carrier 3-Zone
system uses motorized air volume control dampers (also called
zone dampers) to regulate the flow of conditioned air into the
zones.

INSTALLATION

Step 1—Check Equipment and Job Site

INSPECT EQUIPMENT — File claim with shipping company,
prior to installation, if shipment is damaged or incomplete.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 1144
Tab 3a 5a 2a 5a

PC 101 Catalog No. 809-50009 Printed in U.S.A. Form ZONEKIT-15SI Pg 1 11-04 Replaces: NEW

Step 2—Component Location and Wiring
Considerations

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury
or death.
Turn off unit before routing routing control wiring or any
service operation. Remember, there may be more than one
power supply to unit.

All wiring must comply with national, local, and state codes.
LOCATING CARRIER 3-ZONE SYSTEM — All wiring is run

back to the Carrier 3-Zone System. Select a location near the
furnace or fan coil where wiring from each thermostat, each
damper actuator, and the equipment itself can come together
easily.

The Carrier 3-Zone System is approved for indoor use only and
should never be installed with any of its components exposed to
the elements. It may be installed in any area where the temperature
remains between 32° and 158°F, and there is no condensation. The
cover must be installed to prevent damage from other sources. Do
not locate where it will be accessible to children. It may be
mounted in either vertical or horizontal position. Remember that
wiring access is likely the most important consideration.

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage.
To prevent possible damage to Carrier 3-Zone System, do not
mount control on plenum, duct work, or flush against furnace.

LOCATING THERMOSTATS — For proper operation, each
thermostat must accurately measure the temperature within its
zone.

For accurate temperature measurement, the following guidelines
should be followed:

Thermostat should be mounted:

• Approximately 5 ft. (1.5m) from floor.

• Close to the center of its zone, preferably on an inside wall.

• On a section of wall without pipes or duct work.
Thermostat should NOT be mounted:

• Close to a window, on an outside wall, or next to a door leading
to the outside.

• Where it will be exposed to direct light and heat from a lamp,
sun, fireplace, or other temperature radiating object which may
cause a false reading.

• Close to or in direct airflow from supply registers and return-air
grilles.

• In areas with poor air circulation, such as behind a door or in
an alcove.

WIRING CONSIDERATIONS — All wiring in the Carrier Three­Zone system may be unshielded. Ordinary thermostat wire is ideal.
Use 22 gage or larger for normal wiring. Lengths over 100 ft.
should use 20 gage or larger wire.

Each damper actuator requires 3 conductors. The connection to
thermostats and equipment (furnace or fan coil) could require as
many as 8 conductors for a multi-stage installation. The leaving air
temperature (LAT) and heat pump temperature (HPT)—(used with
heat pumps only) sensors require 2 conductors each.

Cables with excess conductors are acceptable. Cut off or fold back
and tape any unneeded conductors.

Plan the routing of wiring early to avoid possible problems later
on.

Remember all wires converge at the Carrier 3-Zone system, so its
location is important.

Step 3—Install Components

INSTALL CARRIER 3-ZONE SYSTEM
The Carrier 3-Zone System is designed so that wires can enter it

from behind, above, or below. Plan wire routing before mounting.

1. Open door to access eight mounting screw slots

2. Mount to wall using four screws and wall anchors provided.

3. Level and tighten screws.

INSTALL THERMOSTATS

1. Follow manufacturer’s supplied instructions for installing
thermostats.

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage.
Improper wiring or installation may damage the thermostats.
Check to make sure wiring is correct before proceeding with
installation or turning on unit.

Step 4—Install Zone Dampers

Proper selection and sizing of dampers is important for proper
system operation. Selection and sizing information is not provided
in this installation instruction.

If duct work requires multiple dampers for a single zone, up to 5
dampers may be wired in parallel.

Zone dampers may be installed in any position.
Install dampers so that actuator is visible for inspection and

accessible in the event it would ever need to be serviced. The black
mark on the end of damper shaft represents position of damper
blade.

The 45 degree actuators on round ducts have their mechanical
stops set at 45 degrees. DO NOT CHANGE THIS SETTING.
Doing so will allow the actuator to close when it is trying to open.
If an actuator is removed, it must be properly aligned when it is
reinstalled. Do this by rotating the actuator and the blade to their
closed positions and then tightening the actuator to the shaft. This
assures alignment at the closed position. (Pressing the blade
release button releases the motor and allows the actuator to be
manually turned.)

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in equipment
damage.
When dampers are located in an unconditioned space, con­densation is likely to occur in cooling. Regular and severe
condensation will damage the actuator. To prevent conden­sation and losses, all dampers and ductwork in unconditioned
space must be insulated or otherwise protected.

Whenever condensation might occur, it is recommended that
plastic actuator covers (Part# DAMPACTXXCOV) be used over
the actuator. These covers can help prevent condensation on
actuators by locking out ambient humidity. Insulation may be
applied over the cover to minimize heat transfer.

To install, place the cover over actuator and seal in place over the
surrounding insulation with duct tape on all four sides. Sealing

2

need not be perfect because there will be positive pressure inside
the cover. Do not mount the dampers with their actuators hanging
directly beneath the ductwork. It is best to mount the actuator
facing in either the three or nine o’clock position.

For specific duct types, follow instructions below:
ROUND METAL DUCT WORK

1. Crimp end of branch duct.

2. Slip end of zone damper over end of duct work. Use
self-tapping sheet metal screw to secure. (See Fig. 2.)

3. Properly seal joint using duct tape, mastic, or other approved
method. Do not allow mastic to come in contact with actuator.

4. Insulate damper using 1-1/2 in. to 2-in. insulation. (Check
your local codes.)

NOTE: All zone dampers and duct work must be properly
supported according to local codes or SMACNA standards.

RECTANGULAR METAL DUCT WORK

1. Make connections using S-lock and drives. (See Fig. 2.)

2. Properly seal joint using duct tape, mastic, or other approved
method. Do not allow mastic to come in contact with actuator.

MOUNTING

HUB

1

2

1 / " TO 2"

INSULATION

A95131

Fig. 3—Insulated Rectangular Metal Duct Work

ROUND FLEXIBLE DUCT WORK

1. Slip 1 end of flexible duct work over 1 end of zone damper.
(See Fig. 4.)

FLEXIBLE

DUCT

ZONE

DAMPER

ACTUATOR
HOUSING

OPN

CLS

QUICK BLADE

RELEASE

BUTTON (RED)

Fig. 1—Damper 24-vac Connections

SUPPLY
AIR DUCT

Fig. 2—Rectangular Metal Duct Work

COM

MOUNTING
PLATE

FIELD
INSTALLED
POWER WIRING

S-LOCK

DRIVE

C02083

ZONE
DAMPER

A92478

3. Insulate damper using 1-1/2 in. to 2-in. insulation. (Check
your local codes.) (See Fig. 3.)

Fig 4—Round Flexible Duct Work

A95132

2. Secure flexible duct to zone damper using SMACNA or other
approved method.

3. Properly seal joint using duct tape, mastic, or other approved
method. Do not allow mastic to come in contact with actuator.

4. Insulate damper using 1-1/2 in. to 2-in. insulation. (Check
your local codes.) (See Fig. 5.)

NOTE: All zone dampers and duct work must be properly
supported according to local codes or SMACNA standards.

1

2

/ ″ STEEL STRAP

A95133

Fig. 5—Insulated Round Duct Work

RECTANGULAR FIBROUS GLASS DUCT WORK

1. Insert 1 end of zone damper into 1 end of fibrous glass duct
work approximately 2 to 3 in. (See Fig. 6.)

2. Screw field-supplied screws and tabs into zone damper.

3. Properly seal joint using duct tape, mastic, or other approved
method. Do not allow mastic to come in contact with actuator.

4. Insulate damper using 1-1/2 in. to 2-in. insulation. (Check
your local codes.) (See Fig. 7.)

3

FIBROUS
GLASS
DUCTWORK

2″ TO 3″

FIELD
SUPPLIED
SCREWS

ZONE
DAMPER

A92480

Fig. 6—Rectangular Fibrous Glass Duct Work

1

2

1 / ″ TO 2″
INSULATION

A95134

Fig. 7—Insulated Rectangular Fibrous Glass

Duct Work

Step 5—Install Barometric Bypass Damper
NOTE: The barometric bypass damper is a critical part of Carrier

3-Zone System for controlling noise at minimum airflow. A
barometric bypass should be installed unless the duct work and
indoor unit have been sized for use without a bypass.

The bypass should be installed according to local codes and
SMACNA standards. Be sure bypass is properly supported.

For proper installation, refer to Installation Instructions packaged
with barometric bypass.

Step 6—Install Leaving Air Temperature (LAT) Sensor
NOTE: The supplied LAT sensor must be installed for normal

operation. Heat pump systems may use an optional HPT (heat
pump temperature) sensor for added protection. These sensors
protect the equipment when leaving air temperatures approach
excessive levels.

Locate LAT sensor in main supply trunk after heating and cooling
coil and before bypass damper and first branch. The LAT sensor is
radiant shielded to prevent heat from affecting correct air tempera­ture.

1. Drill a 1/4-in. hole at location in supply trunk where sensor
will be installed.

2. Insert sensor in hole and use as a template to mark the 2
mounting holes.

3. Drill two 1/16-in. holes to accept No. 6 screws through
pre-drilled holes in duct temperature sensor back plate.

4. Use 2 No. 6 sheet metal screws to mount duct temperature
sensor to unit.

5. Connect sensor to 2-conductor wire using provided wire nuts.
(See Fig. 9, 10, or 11 for connection to Carrier 3-Zone
System.)

Step 7—Install Heat Pump Temperature (HPT) Sensor

The optional HPT sensor is recommended in all heat pump/fan coil
installations. If an optional HPT sensor is not used, the 10K ohm
resistor attached to the two HPT terminals on the board must be
left in place. The HPT sensor measures the temperature of the air
leaving the indoor coil. The sensor is to be installed downstream of
the indoor coil but before the electric heaters. It can be installed

through the wall of the fan coil or may be located entirely inside
the fan coil near the blower inlet. Anchor firmly in place with cable
ties so that it cannot interfere with the blower wheel.

SYSTEM WIRING

Wiring the system is best done in four steps. Thermostats,
Equipment, Dampers, and Remainder. The descriptions below and
Table 1 will help you choose the correct wiring diagram for your
system. Table 1 also shows the proper setting of dipswitches 9 and
10 for each diagram. Based on the equipment, 3-zone control, and
thermostat type, select the appropriate wiring diagram. Terminal
designations on all the thermostats are those of Carrier thermostats.
Other brands may vary somewhat. Wiring diagrams and 3-Zone
Control board layouts are located at the end of this Installation
Instruction.

Table 1—Wiring Diagram Selection Chart

WIRING DIAGRAM EQUIPMENT

Fig. 10

Fig. 11

Fig. 12

Fig. 13

Fig. 14

Fig. 15

1-spd. AC,
1-Stg. heat

1-spd. AC,

1 or 2-stg. heat

1-spd. HP,

1-stg. aux heat

1-spd. HP,

1-stg. aux heat

2-spd. AC,

1 or 2-stg. heat

2-spd. HP,

1-stg. aux heat

3-ZONE

TYPE

HP/2S AC ON ON

HP/2S HP OFF OFF

HP/2S AC (2 ht) OFF ON

HP/2S 2S (AC) ON ON

HP/2S 2S (HP) OFF OFF

Fig. 8 - Shows the board layout for the AC Control.
Fig. 9 - Shows the board layout for the HP/2S Control.
Fig. 10 - Shows the 3-Zone AC Control wiring. It supports only 1

stage cooling and 1 stage heating.
Fig. 11 - Shows that the 3-Zone HP/2S Control may be used in 1
stage cooling and 1 or 2 stage heating applications. For 2 stage
heating, the stat may be a 2 stage heat AC stat or a HP stat
converted to AC. (Carrier HP stats can be field converted to 2 stage
heat AC stats.)
Fig. 12 - Shows the conventional HP system, using a HP stat. Only
single stage auxiliary heat is supported for heat pump systems.
Using the HP stat allows control of emergency heat directly from
the stat.
Fig. 13 - Is also a HP system, but uses an AC stat with 2 stage
heating instead of a HP stat. (Carrier HP stats can be field
converted to 2 stage heat AC stats.) Here, emergency heat can only
be selected by a switch on the 3-Zone Control.
Fig. 14 - Is a 2 speed AC system and may have 1 or 2 stages of
heat. An HP/2S Control and a 2S stat set for AC operation must be
used.
Fig. 15 - Is for a 2 speed HP. It requires an HP/2S Control and a
2S stat set for HP operation. Only single stage auxiliary heat is
supported for heat pump systems.

Step 1—Wire Thermostats

All zone thermostats are wired identically, so only the Zone 1
thermostat is shown on the wiring diagrams. For physical location
of connections on 3-Zone Control refer to Fig. 8 (AC Control) or
9 (HP Control).

Battery or power stealing thermostats may not require the C
connection. Refer to thermostat Installation Instructions. Be care­ful not to cross zone numbers.

Step 2—Wire Equipment

Again, from the selected Fig. 10 through 13, make each connection
as shown at the indoor and outdoor units and the 3-zone Control.

STAT
TYPE

AC AC not present not present

4

SWITCH 9 SWITCH 10